Apparatuses and methods for induction heating

ABSTRACT

A heating apparatus for induction heating is disclosed. The heating apparatus may comprise a bearing ring, at least one bearing element disposed in the bearing ring, and a braze material adjacent to the at least one bearing element and the bearing ring. The heating apparatus may additionally comprise an inductor positioned radially adjacent to at least a portion of the bearing ring. A current source may be electrically coupled to the inductor. A bearing orienting member may also abut a surface of the at least one bearing element. The bearing orienting member may orient a surface of the at least one bearing element. A heating method is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 12/425,304filed on 16 Apr. 2009, the disclosure of which is incorporated herein,in its, entirety, by this reference.

BACKGROUND

Conventional bearing apparatuses including bearing surfaces that moverelative to one another are known in the art. For example, conventional,so-called “thrust bearings” and some embodiments of radial bearingsinclude bearing surfaces that at least partially contact and move orslide relative to one another. Such bearing surfaces may include asuperhard material for resisting wear during use of the bearingapparatus. In one example, bearing surfaces in a bearing apparatus maycomprise a hard material such as diamond (e.g., polycrystallinediamond).

One application for bearing apparatuses, such as thrust bearings andradial bearings, is in drilling equipment utilized in subterraneandrilling. Particularly, drilling motors have been utilized for drillingboreholes into subterranean formations, especially for oil or gasexploration. In a typical downhole drilling motor, the motor issuspended at the lower end of a string of drill pipe comprising a seriesof pipe sections connected together at joints and supported from thesurface. A rotary drill bit (e.g., a fixed cutter drill bit, roller conedrill bit, a reamer, etc.) may be supported below the drilling motor(via pipe sections, drill collars, or other structural members as knownin the art) or may be directly connected to the downhole motor, ifdesired. Drilling fluid is commonly circulated through the pipe stringand the motor to generate torque within the motor, causing the rotarydrill bit to rotate. The drilling fluid may then be returned to thesurface through the annular space between the drilled borehole and thedrill string and may carry the cuttings of the subterranean formation tothe surface.

Downhole drilling motors may include bearing apparatuses, such as thrustbearings or radial bearings. More particularly, conventional downholedrilling motors may include a non-rotating bearing ring that does notrotate and is connected to a housing of the motor and a rotating bearingring that rotates with the output shaft of the downhole fluid motor. Inone embodiment, bearing assemblies comprised of a plurality of hardbearing elements, such as diamond bearing elements, may be coupled tothe rotating bearing ring and the non-rotating bearing ring. The bearingelements are positioned adjacent one another so that the diamond bearingsurfaces of the non-rotating bearing ring and rotating bearing ringcontact one another.

Bearing elements have traditionally been secured to bearing apparatusesthrough using various methods, including brazing the bearing elements toa rotating bearing ring and a non-rotating bearing ring of a bearingapparatus. However, conventional brazing techniques typically requireexposing the parts to be brazed to high temperatures for extendedperiods of time to melt a brazing filler metal used to braze the parts.Bearing parts, such as rotating bearing rings and non-rotating bearingrings, are often placed in a heating oven for a few hours in order toheat the parts and the brazing filler metal to the appropriate brazingtemperature.

SUMMARY

According to at least one embodiment, a heating apparatus may comprise arotational support member having a rotational axis about which therotational support member is configured to rotate. The heating apparatusmay also comprise an inductor positioned adjacent to at least a portionof a bearing ring. The rotational support member may be configured torotate relative to the inductor.

According to additional embodiments, the bearing orienting member may beconfigured to rotate in conjunction with the rotational support member.The heating apparatus may also comprise an alternating current sourceelectrically coupled to the inductor. Additionally, the inductor maysurround the rotational axis of the rotational support member. Further,the rotational support member may comprise a chuck configured toreleasably secure a bearing ring to the rotational support member. Theinductor can include at least one induction coil.

According to certain embodiments, the inductor includes a firstinduction coil and a second induction coil. The first induction coil mayradially surround at least a portion of the second induction coil. Thefirst induction coil may radially surround at least a portion of abearing ring, and the bearing ring at least partially surrounds thesecond induction coil.

According to various embodiments, a heating apparatus may comprise abearing ring comprising a conductive material, at least one bearingelement disposed in the bearing ring, and a braze material adjacent tothe at least one bearing element and the bearing ring. The heatingapparatus may also comprise an inductor positioned radially adjacent toat least a portion of the bearing ring. The heating apparatus mayfurther comprise a current source electrically coupled to the inductor.The at least one bearing element may be at least partially disposedwithin at least one recess defined in the bearing ring.

The heating apparatus may additionally comprise a rotational supportmember supporting the bearing ring. The current source electricallycouple to the inductor may be an alternating current source. Theinductor may include a first induction coil and a second induction coil.The first induction coil and the second induction coil may be positionedsuch that the first induction coil radially surrounds at least a portionof the second induction coil. At least a portion of the bearing ring maybe positioned radially between the first induction coil and the secondinduction coil.

According to at least one embodiment, a heating apparatus may comprise abearing ring, at least one bearing element disposed in the bearing ring,and a braze material adjacent to the at least one bearing element andthe bearing ring. The heating apparatus may also comprise an inductorpositioned radially adjacent to at least a portion of the bearing ring.Additionally, the heating apparatus may comprise a bearing orientingmember abutting a surface of the at least one bearing element. Thebearing orienting member may orient a surface of the at least onebearing element. The bearing orienting member may exert a force againstthe surface of the at least one bearing element and the force may bedirected toward the bearing ring.

According to various embodiments, the surface of the at least onebearing element may comprise a bearing contact surface. The bearingcontact surface may comprise a diamond material, such as polycrystallinediamond. The bearing orienting member may have a substantially planarsurface abutting the surface of the at least one bearing element. Thebearing orienting member may also be slidingly engaged with a stationarysupport member. In addition, one or more gaps may be defined in thebearing orienting member between the bearing ring and the stationarysupport member.

According to at least one embodiment, a heating method may comprisepositioning at least one bearing element in a bearing ring such that abraze material is disposed between the at least one bearing element andthe bearing ring. The heating method may comprise passing a currentthrough an inductor to generate a magnetic field from the inductor. Theheating method may also comprise exposing at least a portion of thebearing ring to the magnetic field generated from the inductor.Additionally, the heating method may comprise rotating the bearing ringrelative to the inductor. The heating method may further compriseexerting a force against a surface of the at least one bearing element.The force exerted against a surface of the at least one bearing elementmay be directed toward the bearing ring. The current passed through theinductor may be an alternating current.

According to various embodiments, exposing at least a portion of thebearing ring to the magnetic field generated from the inductor maycomprise heating the bearing ring, the braze material, and thepolycrystalline diamond insert. Additionally, exposing at least aportion of the bearing ring to the magnetic field generated from theinductor may comprise melting the braze material. According to certainembodiments, rotating the bearing ring may comprise rotating the bearingring about a rotational axis that passes through a central portion ofthe bearing ring.

According to additional embodiments, exposing at least a portion of thebearing ring to the magnetic field generated from the inductor maycomprise positioning the bearing ring such that the inductor at leastpartially surrounds the bearing ring. Exposing at least a portion of thebearing ring to the magnetic field generated from the inductor may alsocomprise positioning the bearing ring such that the bearing ring atleast partially surrounds the inductor. The inductor may include a firstinduction coil and a second induction coil. The heating method mayadditionally comprise passing a current through the second inductioncoil to generate a magnetic field from the second induction coil andexposing at least a portion of the bearing ring to the magnetic fieldgenerated from the second induction coil.

According to at least one further embodiment, a heating method maycomprise providing a superabrasive compact that includes a substrate, asuperabrasive material bonded to the substrate, and a base member. Theheating method may comprise providing an inductor proximate to the basemember, rotating the base member, and induction heating the base member.

Features from any of the described embodiments may be used incombination with one another in accordance with the general principlesdescribed herein. These and other embodiments, features, and advantageswill be more fully understood upon reading the following detaileddescription in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate a number of exemplary embodimentsand are a part of the specification. Together with the followingdescription, these drawings demonstrate and explain various principlesof the instant disclosure.

FIG. 1 is a side view of a heating apparatus according to at least oneembodiment.

FIG. 2 is a side view of a portion of a heating apparatus according toan additional embodiment.

FIG. 3 is a side view of a portion of a heating apparatus according toan additional embodiment.

FIG. 4 is a cross-sectional view of a portion of a heating apparatusaccording to an additional embodiment.

FIG. 5 is a perspective view of an inductor forming an induction coilaccording to at least one embodiment.

FIG. 6 is a perspective view of an inductor forming a first inductioncoil and a second induction coil according to an additional embodiment.

FIG. 7 is a perspective view of a bearing ring according to at least oneembodiment.

FIG. 8 is a perspective view of a bearing element according to at leastone embodiment.

FIG. 9 is a cross-sectional view of a bearing ring according to at leastone embodiment.

FIG. 10 is a perspective view of a bearing apparatus according to atleast one embodiment.

FIG. 11 is a perspective view of a bearing apparatus according to anadditional embodiment.

FIG. 12 is a perspective view of an outer bearing ring according to atleast one embodiment.

FIG. 13 is a perspective view of an inner bearing ring according to atleast one embodiment.

FIG. 14 is a perspective view of an outer bearing ring and a portion ofa heating apparatus according to at least one embodiment.

FIG. 15 is a top view of an outer bearing ring and a portion of aheating apparatus according to at least one embodiment.

FIG. 16 is a top view of an inner bearing ring and a portion of aheating apparatus according to at least one embodiment.

FIG. 17 is a perspective view of a portion of a heating apparatusaccording to at least one embodiment.

FIG. 18 is a schematic diagram of an exemplary heating method accordingto at least one embodiment.

FIG. 19 is a schematic diagram of an exemplary heating method accordingto an additional embodiment.

FIG. 20 is a schematic diagram of an exemplary heating method accordingto an additional embodiment.

Throughout the drawings, identical reference characters and descriptionsindicate similar, but not necessarily identical, elements. While theexemplary embodiments described herein are susceptible to variousmodifications and alternative forms, specific embodiments have beenshown by way of example in the drawings and will be described in detailherein. However, the exemplary embodiments described herein are notintended to be limited to the particular forms disclosed. Rather, theinstant disclosure covers all modifications, equivalents, andalternatives falling within the scope of the appended claims.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present invention relates generally to apparatuses and methods forbrazing bearing components, such as bearing rings that include bearingelements comprising superhard materials. “Superhard,” as used herein,refers to any material having a hardness that is at least equal to ahardness of tungsten carbide. Additionally, as used herein, the term“bearing ring” refers to a bearing rotor, a bearing stator, and/or anyother bearing ring suitable for use in a thrust bearing, a radialbearing, and/or any other suitable bearing apparatus. In one embodiment,a bearing ring may include polycrystalline diamond inserts or compactsdefining a plurality of surfaces that move relative to one another. Suchbearing apparatuses may encompass so-called thrust bearings, radialbearings, or other bearing apparatuses including bearing surfaces thatmove in relation to one another, without limitation.

When the bearing assemblies involve the use of stainless steel and arebrazed in the presence of flux, the high temperatures and extendedbrazing times can lead to corrosion of the stainless steel around theinterfaces between the brazing filler metal and the stainless steelparts. This phenomenon is referred to as braze interface corrosion. Theflux material tends to selectively draw chromium out of the stainlesssteel, leaving a layer of chromium free steel. The chromium free steelis susceptible to corrosion attack, particularly in the presence ofchlorides. This results in the formation of crevices between the brazingfiller metal and the brazed part. Extended brazing times may weakenbraze joints between the bearing elements and the rotating bearing ringor non-rotating bearing ring of the bearing apparatus, potentiallyresulting in braze joint failure.

FIG. 1 is a side view of an exemplary heating apparatus 20 according toat least one embodiment. As illustrated in this figure, heatingapparatus 20 may comprise a current source 22, an inductor 24, arotational support member 30, a bearing orienting member 34, and asupport member 46. According to various embodiments, a bearing ring 32may be mounted to heating apparatus 20. Current source 22 may compriseany current source that provides or is capable of providing anelectrical current to inductor 24. For example, current source 22 mayprovide an alternating current to inductor 24.

Inductor 24 may comprise any type of wire, tubing, or rod capable ofconducting an electrical current provided by current source 22. Inductor24 may be formed from any suitable conductive material or combination ofmaterials, such as, for example, copper. At least a portion of inductor24 may be formed into one or more coils, such as first induction coil26. According to at least one embodiment, an alternating currentprovided to inductor 24 by current source 22 may be conducted throughfirst induction coil 26. As first induction coil 26 conducts analternating current, a magnetic field (i.e., an electromagnetic field)may be generated from first induction coil 26.

As shown in FIG. 1, first induction coil 26 may at least partiallysurround bearing ring 32 when rotational support member 30 is suitablypositioned. According to at least one embodiment, a second inductioncoil (see, e.g., second induction coil 28 in FIG. 4) may be positionedsuch that bearing ring 32 at least partially surrounds the secondinduction coil. A second induction coil may comprise inductor 24 and maybe electrically coupled with first induction coil 26. As shown in FIG.1, a portion of inductor 24 may lead to a second induction coilproximate to an interior area of bearing ring 32.

According to various embodiments, rotational support member 30 may belowered and raised to ease mounting and removal of bearing ring 32 onrotational support member. Bearing ring 32 may be supported onrotational support member 30 such that it may be rotated within aninterior portion of first induction coil 26 when rotational supportmember 30 is raised. Additionally, bearing ring 32 may be disposedadjacent to first induction coil 26 such that at least a portion ofbearing ring 32 interacts with a magnetic field generated from firstinduction coil 26. For example, bearing ring 32 may be positionedadjacent to first induction coil 26 so that first induction coil 26surrounds at least a portion of bearing ring 32.

Bearing orienting member 34 may be positioned such that it is adjacentto bearing ring 32 when rotational support member 30 is raised. Bearingorienting member 34 may contact one or more bearing elements disposed inbearing ring 32 (see, e.g., bearing elements 31 in FIGS. 3 and 4).Bearing orienting member 34 may generally align surfaces (see, e.g.,bearing contact surfaces 52 in FIG. 3) of the one or more bearingelements disposed in bearing ring 32 in a substantially common plane,the surfaces forming a substantially planar bearing contact surface.According to at least one embodiment, bearing orienting member 34 may beslidingly engaged with a support member 46. Support member 46 maysupport bearing orienting member 34 while allowing rotation of bearingorienting member 34 in conjunction with rotation of bearing ring 32. Asshown in FIG. 1, support member 46 may support bearing orienting member34 from above, and additionally, support member 46 may be secured to asupport structure or frame, such as stationary support structure 47located above and/or around support member 46 and/or additional portionsof heating apparatus 20. Stationary support structure 47 may comprise astationary support framework.

FIG. 2 illustrates a portion of an exemplary heating apparatus 20 inwhich rotational support member 30 is in a first position and a bearingring 32 is not mounted to rotational support member 30. As shown in thisfigure, rotational support member 30 may include a chuck 36 and a heightadjustment mechanism 40. Chuck 36 may include two or more chuck jaws 37and two or more support arms 38 attached to chuck jaws 37. In at leastone embodiment, chuck 36 may comprise three chuck jaws 37, each of whichmay be attached to a support arm 38. End portions of support arms 38 maybe formed to accept a bearing ring 32. For example, as shown in FIG. 2,an end portion of each of support arms 38 may comprise a support recess39 that is shaped to accept a corresponding portion of bearing ring 32.In additional embodiments, support recesses 39 defined in support arms38 may be stepped so that bearing rings of varying diameters may bemounted to support arms 38. In at least an additional embodiment,bearing ring 32 may be mounted directly to chuck 36 or to one or moresupport arms extending from rotational support member 30.

An operator may load bearing ring 32 onto support arms 38 by openingchuck jaws 37 such that bearing ring 32 may be seated in supportrecesses 39 on support arms 38, wherein the support recesses 39 arefacing radially inward. Chuck jaws 37 may be opened to a diameter wherebearing ring 32 is loosely seated in support recesses 39. Subsequently,chuck jaws 37 may be moved radially inward, causing support arms 38 tolikewise move radially inward. Accordingly, support recesses 39 maycontact outer portions of bearing ring 32, thereby holding bearing ring32. Following brazing, bearing ring 32 may be removed from rotationalsupport member 30 by opening chuck jaws 37 to a diameter sufficient torelease rotational support member 30 from support arms 38.

In other embodiments, the support recesses 39 are arranged facingradially outward. An operator may load bearing ring 32 onto support arms38 by closing chuck jaws 37 such that bearing ring 32 may be seated insupport recesses 39 on support arms 38. Chuck jaws 37 may be retractedor closed to a smaller diameter where bearing ring 32 is loosely seatedin support recesses 39. Subsequently, chuck jaws 37 may be movedradially outward, causing support arms 38 to likewise move radiallyoutward. Accordingly, support recesses 39 may contact inner portions ofbearing ring 32, thereby holding bearing ring 32. Following brazing,bearing ring 32 may be removed from rotational support member 30 byclosing or retracting chuck jaws 37 to a smaller diameter sufficient torelease rotational support member 30 from support arms 38.

Rotational support member 30 may also include a height adjustmentmechanism 40 configured to adjust the height of rotational supportmember 30, and likewise, to move a bearing ring 32 mounted to rotationalsupport member 30 to a selected height H, as shown in FIG. 2 to be adistance measured from support recesses 39 to a surface 41 of the heightadjustment mechanism 40. Height adjustment mechanism 40 may comprise asupport post or other suitable supporting member. Additionally, heightadjustment mechanism 40 may comprise a height adjustment deviceconfigured to raise and lower portions of rotational support member 30,including chuck 36. Height adjustment mechanism 40 may comprise apiston, a gear, and/or any other suitable mechanism for moving portionsof rotational support member 30. In at least one embodiment, heightadjustment mechanism 40 may produce a force toward bearing orientingmember 34 such that bearing ring 32 and/or bearing elements (see, e.g.,bearing elements 31 in FIG. 3) disposed in bearing ring 32 may be forcedagainst bearing orienting member 34.

Bearing orienting member 34 may comprise one or more gaps 44 defined ina portion of bearing orienting member 34, as shown in FIG. 2. Accordingto various embodiments, bearing orienting member 34 may be rotationallyengaged with a support member 46. Additionally, bearing orienting member34 may comprise a lip 48 extending around a peripheral portion ofbearing orienting member 34. One or more engagement members 50 may beattached to support member 46 and each engagement member 50 may have atrack or recess configured to engage lip 48 of bearing orienting member34. Lip 48 of bearing orienting member 34 may be slidingly engaged withengagement members 50, and accordingly, lip 48 may slide throughengagement members 50 as bearing orienting member 34 rotates relative tosupport member 46.

A portion of inductor 24 may form a first induction coil 26, as shown inFIG. 2. First induction coil 26 may extend radially around an area wherea bearing ring 32 may be positioned when bearing ring 32 is mounted torotational support member 30 and rotational support member 30 issuitably positioned. According to certain embodiments, a portion ofinductor 24 may form a second induction coil disposed radially inwardrelative to first induction coil 26.

FIG. 3 illustrates a portion of bearing apparatus 20 shown in FIG. 2 inwhich a bearing ring 32 is mounted to rotational support member 30 androtational support member 30 is in a position. As illustrated in thisfigure, bearing ring 32 may be mounted on support arms 38 attached tochuck 36 of rotational support member 30, and height adjustmentmechanism 40 of rotational support member 30 may be disposed in a raisedposition. Additionally, one or more bearing elements 31 may be disposedin bearing ring 32. For example, bearing elements 31 may be at leastpartially disposed within one or more recesses defined in bearing ring32.

At least a portion of bearing elements 31 may protrude from a portion ofbearing ring 32. For example, a portion of bearing elements 31 mayextend into recesses defined in bearing ring 32 and a remaining portionof bearing elements 31 may extend outwardly from bearing ring 32. In atleast one embodiment, bearing elements 31 may extend from bearing ring32 in a direction substantially parallel to an axis around which bearingring 32 (e.g., a thrust bearing ring) is substantially centered.Further, bearing elements 31 may be suitably radially positioned withrespect to an axis around which bearing ring 32 (e.g., a radial bearing)is substantially centered. Additionally, at least one bearing element 31may comprise a bearing contact surface 52 facing away from a portion ofbearing ring 32 in which bearing element 31 is disposed. Bearing contactsurface 52 may be configured to contact a portion of another adjacentbearing contact surface in a bearing apparatus. For example, a bearingcontact surface 52 of a bearing element 31 mounted to a rotor in athrust bearing apparatus may be configured to contact a bearing contactsurface 52 of a bearing element 31 mounted to a stator in the thrustbearing apparatus.

Bearing orienting member 34 may include a bearing orienting surface 42configured to contact and orient bearing elements 31 disposed in bearingring 32 mounted to rotational support member 30. According to at leastone embodiment, bearing ring 32 may be mounted to rotational supportmember 30 and may be positioned via height adjustment mechanism 40 untilone or more surfaces of bearing elements 31 disposed in bearing ring 32contact bearing orienting surface 42. Bearing orienting member 34 maycomprise one or more gaps 44 defined in a portion of bearing orientingmember 34. For example, as illustrated in FIG. 3, a plurality of gaps 44may be defined in bearing orienting member 34 at locations on bearingorienting member 34 between bearing orienting surface 42 and a part ofbearing orienting member 34 adjacent to support member 46.

As shown in FIG. 3, bearing contact surfaces 52 of one or more bearingelements 31 disposed in bearing ring 32 may face toward bearingorienting member 34 when bearing ring 32 is mounted to rotationalsupport member 30. Additionally, bearing contact surfaces 52 of one ormore bearing elements 31 disposed in bearing ring 32 may contact bearingorienting surface 42 of bearing orienting member 34. According to atleast one embodiment, bearing orienting surface 42 may comprise asubstantially planar surface of bearing orienting member 34. Forexample, bearing orienting surface 42 may be substantially planar andmay be configured to contact one or more bearing contact surfaces 52 ofbearing elements 31.

Accordingly, bearing contact surfaces 52 of bearing elements 31 may besubstantially aligned with bearing orienting surface 42 and/or eachother. Optionally, the plurality of bearing contact surfaces 52 ofbearing elements 31 may be substantially aligned by bearing orientingsurface 42 of bearing orienting member 34 such that they are configuredto contact adjacent bearing contact surfaces in a bearing apparatus.According to other embodiments, bearing orienting member 34 does nothave a substantially planar bearing orienting surface 42 as shown inFIG. 3, but rather, bearing orienting member 34 may comprise a one ormore bearing orienting surfaces of varying shapes and configurationsconfigured to abut and/or orient one or more bearing elements 31 inbearing ring 32. Bearing orienting member 34 may orient and maintaineach of bearing elements 31 in a desired position within bearing ring 32during brazing of bearing elements 31 to bearing ring 32 using heatingapparatus 20.

FIG. 4 is a cross-sectional view of a portion of the heating apparatusshown in FIG. 3. As illustrated in FIG. 4, bearing ring 32, rotationalsupport member 30, and/or bearing orienting member 34 may be generallycentered with respect to rotational axis 54. Rotational support member30 may substantially surround rotational axis 54 and at least a portionof rotational support member 30, including chuck 36, may rotate aboutrotational axis 54. Similarly, a bearing ring 32 mounted to rotationalsupport member 30 may substantially surround rotational axis 54 and atleast a portion of bearing ring 32 may rotate about rotational axis 54.

Bearing orienting member 34 and/or bearing ring 32 mounted to rotationalsupport member 30 may substantially surround rotational axis 54, asillustrated in FIG. 4. Bearing ring 32 may comprise any suitable shapeand configuration, as discussed above. According to at least oneembodiment, bearing ring 32 may comprise a substantially annular shapewith respect to rotational axis 54.

Similarly, bearing orienting member 34 may comprise any suitable shapeand configuration, as discussed above. According to various embodiments,bearing orienting member 34 may comprise a substantially annular shapehaving a central portion surrounding rotational axis 54. Bearingorienting member 34 may be substantially centered with respect torotational axis 54. According to certain embodiments, bearing orientingmember 34 may comprise a substantially annular shape. As shown in FIG.4, bearing orienting member 34 may be positioned adjacent to bearingring 32 mounted to rotational support member 30 and/or adjacent to oneor more bearing elements 31 positioned in bearing ring 32.

According to at least one embodiment, as described above, bearingorienting member 34 may be rotationally and/or slidingly engaged withsupport member 46. Bearing orienting member 34 may comprise a lip 48extending around a peripheral portion of bearing orienting member 34.One or more engagement members 50 may be attached to support member 46and each engagement member 50 may have a track or engagement recess 56configured to engage lip 48 of bearing orienting member 34. Lip 48 ofbearing orienting member 34 may be slidingly engaged with engagementrecesses 56 of engagement members 50, and accordingly, lip 48 may slidethrough engagement members 50 as bearing orienting member 34 rotatesrelative to support member 46. According to certain embodiments, asillustrated in FIG. 4, one or more bearings 58 may be disposed betweenbearing orienting member 34 and support member 46. For example, bearing58 (e.g., a ball bearing, roller bearing or other bearing as known inthe art) may be disposed between bearing orienting member 34 and supportmember 46. Bearing 58, or any other suitable device, may be used tofacilitate rotation of bearing orienting member 34 relative to supportmember 46.

As further illustrated in FIG. 4, first induction coil 26 may bedisposed radially adjacent to bearing ring 32, and additionally, asecond induction coil 28 may be disposed radially adjacent to firstinduction coil 26 and/or a bearing ring 32 mounted to rotational supportmember 30. Inductor 24 may extend over a portion of bearing ring 32,bearing orienting member 34, and/or support member 46 as illustrated.Second induction coil 28 and first induction coil 26 may both be formedfrom a common electrical conductor. According to additional embodiments,second induction coil 28 and first induction coil 26 may be formed fromseparate electrical conductors. As shown in FIG. 4, first induction coil26 and second induction coil 28 may be radially adjacent to bearing ring32, bearing orienting member 34, and/or bearing elements 31.

In additional embodiments, bearing orienting member 34 may comprise oneor more gaps 44 defined in a portion of bearing orienting member 34. Forexample, as illustrated in FIG. 4, a plurality of gaps 44 may be definedin bearing orienting member 34 at locations on bearing orienting member34 between bearing orienting surface 42 and a part of bearing orientingmember 34 adjacent to support member 46. Bearing orienting member 34 maybe structure to limit conduction of heat from a portion of bearingorienting member 34 adjacent bearing ring 32 to other portions ofbearing orienting member 34 disposed adjacent to support member 46. Forexample, gaps 44 may limit conduction of heat from bearing ring 32 toother portions of heating apparatus 20, including support member 46,engagement member 50, and/or bearing 58. Similarly, support arms 38 onrotational support member 30 may limit conduction of heat from bearingring 32 to other portions of heating apparatus 20, including, forexample, chuck 36 and height adjustment mechanism 40, since large gapsare formed between bearing ring 32 and the other portions of rotationalsupport member 30.

FIGS. 5 and 6 are perspective views of exemplary inductors 24 accordingto various embodiments. As illustrated in FIG. 5, inductor 24 may form afirst induction coil 26. First induction coil 26 may comprise one ormore substantially complete turns of inductor 24. For example, as shownin FIG. 5, induction coil 26 may comprise at least two substantiallycomplete turns of inductor 24. However, first induction coil 26 may beformed to any suitable shape or size, without limitation. For example,first induction coil 26 may have a generally circular or cylindricalshape configured to at least partially surround an outer diameter of abearing ring 32.

Inductor 24 may comprise any suitable material capable of conducting anelectrical current provided by a current source (see, e.g., currentsource 22 in FIG. 1) Inductor 24 may be formed from any suitableconductive material or combination of materials, such as, for example,copper and/or any other suitable conductive metal. Inductor 24 maycomprise any suitable diameter wire, tubing, or rod. In variousembodiments, an induction coil formed from a relatively narrower turndiameter tubing may comprise more turns (e.g., helical turns) than aninduction coil formed from a relatively wider turn diameter tubing.

FIG. 6 illustrates an inductor 24 that forms first induction coil 26 aswell as a second induction coil 28. As illustrated in FIG. 6, secondinduction coil 28 may comprise one or more substantially complete turnsof inductor 24. First induction coil 26 may be formed to any suitableshape or size, without limitation. For example, second induction coil 28may have a generally circular, cylindrical, or helical shape configuredto be surrounded by an inner diameter of a bearing ring 32. Accordingly,a bearing ring 32 may be positioned such that it is radially betweenfirst induction coil 26 and second induction coil 28, such as whenbearing ring 32 is mounted to heating apparatus 20 (see also FIG. 4).Optionally, first induction coil 26 and second induction coil 28 mayeach be radially adjacent to and separated from bearing ring 32 whenbearing ring 32 is mounted to heating apparatus 20. First induction coil26 and second induction coil 28 may both be formed from a commonelectrical conductor, as illustrated in FIG. 6. According to additionalembodiments, first induction coil 26 and second induction coil 28 may beformed from separate electrical conductors.

FIG. 7 is a perspective view of an exemplary bearing ring 32 that may bebrazed using heating apparatus 20 according to at least one embodiment.Bearing ring 32 may be a rotor, stator, or any other suitable bearingring that may comprise a portion of a bearing apparatus, such as athrust bearing, radial bearing, or combination bearing. As illustratedin FIG. 7, bearing ring 32 may include a bearing ring body 62 and atleast one bearing element 31. Bearing elements 31 may be disposed atleast partially in pockets or recesses (see, e.g., bearing ring recesses66 in FIG. 9) defined in bearing ring body 62 of bearing ring 32.Additionally, bearing elements 31 may extend outward from bearing ringbody 62. For example, as shown in FIG. 7, a portion of bearing ringelements 31 may extend beyond bearing ring body 62, extending past abearing ring surface 70.

Bearing ring body 62 may be a generally annular-shaped or toroid-shapedconfiguration and may have an outer diameter 67 and/or an inner diameter68 generally centered about a bearing ring axis 64. Bearing ring axis 64may be generally or substantially aligned with a rotational axis 54(see, e.g., rotational axis 54 in FIG. 4) that substantially passesthrough central portions of rotational support member 30 and/or bearingorienting member 34 when bearing ring 32 is mounted to rotationalsupport member 30.

Bearing ring body 62 may be formed from any suitable material orcombination of materials, such as, for example, steel and/or othermetallic components. Bearing ring body 62 may comprise a generallyconductive material suitable for generating eddy currents in thepresence of a magnetic field, such as an electromagnetic field generatedfrom an induction coil (see, e.g., first induction coil 26 and secondinduction coil 28 in FIG. 4). In at least one embodiment, eddy currentsmay be generated within bearing ring body 62 when it is disposed withina magnetic field. Eddy currents generated in bearing ring body 62 ofbearing ring 32 may produce heat within bearing ring body 62 throughJoule heating as the eddy currents pass through and encounter resistancein bearing ring body 62. Such heating may also be referred to asinduction heating.

FIG. 8 is a perspective view of an exemplary bearing element 31according to at least one embodiment. As illustrated in this figure,bearing element 31 may include a table 72 bonded to a substrate 74.Table 72 may include a bearing contact surface 52 and may optionallyinclude a chamfer 76. Table 72 may comprise a superhard material, suchas, for example, polycrystalline diamond, cubic boron nitride, siliconcarbide, or any other suitable superhard material. Such a configurationmay provide a bearing contact surface 52 that is relatively wearresistant. Bearing contact surface 52 may be substantially planar andmay be configured to contact another bearing element (e.g., a bearingelement coupled to a rotor) including another bearing surface thatcorresponds to bearing contact surface 52. According to additionalembodiments, bearing contact surface 52 may comprise a non-planarsurface, such as a curved surface (e.g., a convex surface and/or aconcave surface).

In at least one embodiment, bearing element 31 may comprise apolycrystalline diamond compact (“PDC”), as known in the art. In such aconfiguration, substrate 74 may comprise, for example, a carbidesubstrate, such as a cobalt cemented tungsten carbide. Additionally,table 72 may comprise polycrystalline diamond that may include acatalyst (e.g., cobalt, nickel, iron, or any other suitable catalyst)used to facilitate formation of the polycrystalline diamond. Accordingto various embodiments, at least a portion of a catalyst within table 72may be removed using any suitable method (e.g., by acid leaching).Bearing element 31 may be formed to any suitable shape and size, suchas, for example, a substantially cylindrical shape. In at least oneembodiment, bearing element 31 may have a bearing element outer diameter78 that is sized and configured to fit within a corresponding bearingring recess 66 defined in bearing ring body 62 of bearing ring 32 (see,e.g., FIG. 9). Bearing element 31 may have a bearing element outerdiameter 78 that is approximately the same size as or smaller than adiameter of a corresponding bearing ring recess 66. According toadditional embodiments, bearing element 31 may have a bearing elementouter diameter 78 that is larger than a diameter of a correspondingbearing ring recess 66, such as when an interference fit between bearingelement 31 and bearing ring recess 66 of bearing ring 32 is desired.

FIG. 9 is a cross-sectional view of bearing ring 32 taken along line 9-9in FIG. 7. As illustrated in this figure, bearing ring body 62 ofbearing ring 32 may comprise one or more bearing ring recesses 66defined in bearing ring body 62. Bearing ring recesses 66 may extendpartially through bearing ring body 62, as shown. According toadditional embodiments, bearing ring recesses 66 may form aperturesextending completely through bearing ring body 62. Additionally, bearingring recesses 66 may be open to exterior portions of bearing ring body62 adjacent to bearing ring surface 70. Accordingly, bearing elements 31positioned in bearing ring recesses 66 may extend beyond bearing ringbody 62 past bearing ring surface 70.

According to at least one embodiment, bearing ring recesses 66 may eachbe positioned at substantially the same radius (i.e., generally upon acommon bolt circle) and may be substantially equally circumferentiallyspaced with respect to one another and in relation to bearing ring axis64. Likewise, bearing elements 31 disposed in bearing ring recesses 66may also be positioned at substantially the same radius and may besubstantially equally circumferentially spaced with respect to oneanother and in relation to bearing ring axis 64. In one embodiment,bearing ring recesses 66 defined in bearing ring body 62 may besubstantially the same shape and/or size as one another, andcorresponding bearing elements 31 may likewise by substantially the sameshape and/or size. In additional embodiments, bearing recesses 66defined in bearing ring body 62 may differ from each other in shapeand/or size, and corresponding bearing elements 31 may likewise differin shape and/or size.

As additionally shown in FIG. 9, one or more bearing elements 31 may bedisposed in one or more bearing ring recesses 66 defined in bearing ringbody 62 of bearing ring 32. At least a portion of bearing elements 31may extend beyond bearing ring body 62, such that at least a portion oftables 72 extend past a surface of bearing ring body 62, such as bearingring surface 70. Accordingly, bearing contact surface 52 on each ofbearing elements 31 may be positioned beyond an exterior of bearing ringbody 62 facing generally away from bearing ring body 62.

According to various embodiments, a braze material 80 may be disposed atone or more suitable locations to provide braze material for bonding atleast one bearing element 31 to bearing ring body 62. For example, asillustrated in FIG. 9, braze material 80 may be positioned betweenbearing element 31 and bearing ring recess 66 defined in bearing ringbody 62. Braze material 80 may be formed to any suitable shape and sizeand may be disposed at any suitable location such that it will flow(upon at least partially melting) between bearing element 31 and bearingring recess 66. For example, braze material 80 may be positionedadjacent to a bearing element 31 and/or an associated bearing ringrecess 66. In another embodiment, bearing element 31 and bearing ringrecess 66 may be sized such that braze material 80 may be disposed aside wall of bearing ring recess 66 and bearing element 31. Put anotherway, braze material 80 may be disposed between a portion of bearingelement outer diameter 78 and bearing ring recess 66.

In at least one embodiment, braze material 80 may be disposed between anend portion of bearing element 31 and an end portion of bearing ringrecess 66. For example, braze material 80 having a disc shape with adiameter equal to or smaller than a diameter of bearing ring recess 66may be placed in bearing ring recess 66, and bearing element 31 may beplaced in bearing ring recess 66 such that braze material 80 ispositioned in an end portion of bearing ring recess 66. According to atleast one embodiment, a disc of braze material 80 may have a thicknessin a range of approximately 5-10 thousandths of an inch.

Additionally, bearing ring recesses 66 and corresponding bearingelements 31 may be sized such that at least a portion of bearingelements 31 may be positioned within bearing ring recesses 66,respectively. Accordingly, a gap may exist between a bearing element 31and a corresponding bearing ring recess 66. Bearing element 31 andbearing ring recess 66 may be sized such that a gap between bearingelement 31 and bearing ring recess 66 allows braze material 80 to flowinto the gap (e.g., by capillary action or by movement of bearingelement to “squeeze” or otherwise cause braze material 80 to flow). Inat least one embodiment, a gap between bearing element 31 and bearingring recess 66 may have an average thickness in a range of approximately2-5 thousandths of an inch extending circumferentially around bearingelement 31. In various embodiments, braze material 80 positioned in anend portion of bearing ring recess 66 may melt and/or flow through thegap between bearing element 31 and bearing ring recess (e.g., viacapillary action), the braze material surrounding at least a portion ofbearing element 31. In various embodiments, braze material 80 may flowby up to a portion of bearing ring 32 adjacent to bearing ring surface70, and may extend around a circumferential portion of bearing element31 between bearing element 31 and bearing ring recess 66.

Braze material 80 may comprise any material suitable for forming a brazejoint between adjacent parts, such as bearing element 31 and bearingring body 62. Braze material 80 may have a melting point lower than themelting point of bearing element 31 and/or bearing ring body 62.According to various embodiments, braze material 80 may comprise ametal, such as an alloy. Braze material 80 may comprise any suitablemetal or metal alloy composition, including, for example, silver, tin,zinc, copper, nickel, bronze, and/or brass. In at least one embodiment,braze material may comprise a copper-silver alloy. Braze material 80 mayalso be formed to any suitable shape or size prior to brazing,including, for example, a disc, a ring, a sleeve, a wire, a generallyspherical bead, or any other suitable shape configured to be placed twoor more parts suitable for bonding to one another.

Upon heating braze material 80 above its melting temperature, brazematerial 80 may melt, flow, or wet two or more parts, such as betweenbearing element 31 and bearing ring body 62. Subsequently, upon loweringthe temperature of braze material 80, braze material 80 may form a brazejoint between two or more parts, such as bearing element 31 and bearingring body 62. A braze joint formed by braze material 80 may securelyattach bearing element 31 to bearing ring body 62. Additionally, a brazejoint formed by braze material 80 may have sufficient strength and/ortemperature resistance to withstand forces and/or temperatures exertedon bearing element 31 and/or bearing ring body 62, such as forcesexerted during operation.

FIGS. 10 and 11 illustrate various exemplary radial bearing apparatuses182 according to certain embodiments. As illustrated in these figures,radial bearing apparatuses 182 may comprise an outer bearing ring 132and an inner bearing ring 133. Outer bearing ring 132 may be disposedradially surrounding inner bearing ring 133. Additionally, bearingelements (see, e.g., bearing elements 131 in FIGS. 12 and 13) may bedisposed in outer bearing ring 132 and/or inner bearing ring 133 suchthat bearing contact surfaces of bearing elements in outer bearing ring132 contact surfaces of bearing elements in inner bearing ring 133.Outer bearing ring 132 and/or inner bearing ring 133 may each compriseone or more circumferential rows or arrays of bearing elements. Outerbearing ring 132 and/or inner bearing ring 133 may each have a generallyannular-shaped or toroid-shaped configuration and may have an outerdiameter and/or an inner diameter that are generally centered about abearing ring axis 164.

FIGS. 12 and 13 illustrate outer bearing ring 132 and inner bearing ring133 from bearing apparatus 182 shown in FIG. 11. As shown in thesefigures, outer bearing ring 132 and inner bearing ring 133 may each haveat least one row or array of bearing elements 131 disposed on acircumferential surface portion. Outer bearing ring 132 shown in FIG. 12may have an outer diameter 167 and/or an inner diameter 168 that aregenerally centered about bearing ring axis 164. Similarly, inner bearingring 133 shown in FIG. 13 may have an outer diameter 183 and/or an innerdiameter 184 generally centered about bearing ring axis 164. One or morebearing elements 131 may be oriented such that bearing contact surfaces152 of bearing elements 131 face in a substantially radial directionrelative to a bearing ring axis 164. For example, bearing contactsurfaces 152 of bearing elements 131 mounted to outer bearing ring 132may face in a radially inward direction. Further, bearing contactsurfaces 152 of bearing elements 131 mounted to inner bearing ring 133may face in a radially outward direction.

Outer bearing ring 132 may have at least one row or array of bearingelements 131 positioned such that they extend radially inwardly frominner diameter 168. Inner bearing ring 133 may also have at least onerow or array of bearing elements 131 positioned such that they extendradially outwardly from outer diameter 183. Accordingly, bearing contactsurfaces 152 of bearing elements 131 positioned in outer bearing ring132 may face and/or contact bearing contact surfaces 152 of bearingelements 131 positioned in inner bearing ring 133 when outer bearingring 132 and inner bearing ring 133 are operatively coupled in a radialbearing apparatus (see, e.g., radial bearing apparatus 182 in FIG. 11).Bearing contact surfaces 152 of bearing elements 131 mounted to outerbearing ring 132 and/or inner bearing ring 133 may conform to oneanother. For example, bearing contact surfaces 152 of bearing elements131 mounted to outer bearing ring 132 may be substantially concave(e.g., generally cylindrical), and corresponding bearing contactsurfaces 152 of bearing elements 131 mounted to inner bearing ring 133may be substantially convex (e.g., generally cylindrical).

FIG. 14 is a perspective view of an exemplary heating apparatus 120 inwhich bearing orienting member 134 is positioned adjacent to a pluralityof bearing elements 131 disposed in an outer bearing ring 132. FIG. 15is a top view of the exemplary heating apparatus 120 shown in FIG. 14,including outer bearing ring 132 and bearing orienting member 134. Asshown in these figures, bearing orienting member 134 may comprise one ormore bearing contact parts 186, one or more cantilever or bending rods187, and a rod support ring 188. Cantilever rods 187 may be positionedsuch that they extend through holes defined in rod support ring 188. Thebearing contact parts 186 may be selectively positioned and/or adjustedon corresponding cantilever rods 187.

Bearing orienting member 134 may be configured such that one or morebearing contact parts 186 contact bearing elements 131 disposed in outerbearing ring 132. According to at least one embodiment, bearing contactparts 186 may exert force against bearing elements 131 such that bearingelements 131 are held within corresponding bearing ring recesses definedin outer bearing ring 132 (see, e.g., bearing ring recesses 66 definedin bearing ring body 62 of bearing ring 32 in FIG. 9). According toadditional embodiments, bearing contact parts 186 may be configured toorient bearing elements 131. Bearing contact parts 186 may exert forceagainst bearing elements 131 when they are positioned on cantilever rods187 as illustrated in FIGS. 14 and 15. One or more bearing elements 131may be oriented such that surfaces of bearing elements 131 face in asubstantially radial direction relative to a center of outer bearingring 132, including, for example, a radially inward direction (see,e.g., FIG. 12).

For example, one end of each of cantilever rods 187 may be affixed torod support ring 188. As a bearing contact part 186 is positioned on acantilever rod 187, part of bearing contact part 186 may contact abearing element 131 such that a portion of cantilever rod 187 isdeflected away from bearing element 131 by bearing contact part 186.Accordingly, the deflected portion of cantilever rod 187 may exert forceagainst bearing contact part 186, forcing bearing contact part 186against bearing element 131. According to additional embodiments, two ormore bearing contact parts 186 may be positioned on a single cantileverrod 187. Accordingly, bearing orienting member 134 may be used to orienttwo or more rows or arrays of bearing elements 131 on outer bearing ring132.

Additionally, as shown in FIG. 14, outer bearing ring 132 may besupported by support arms 138. For example, outer bearing ring 132 maybe supported by support arms 138 attached to chuck jaws on a chuck of arotational support member (e.g., see, chuck jaws 37 on chuck 36 ofrotational support member 30 in FIG. 3). A bearing orienting member 134may be disposed adjacent to an interior portion of outer bearing ring132 in contact with a plurality of bearing elements 131. Additionally, afirst induction coil 126 formed from an inductor 124 may be positionedadjacent to an exterior of outer bearing ring 132. First induction coil126 may be disposed radially outward from bearing elements 131.

Outer bearing ring 132 may be supported on support arms 138 of arotational support member such that it may be rotated. Outer bearingring 132 may be disposed adjacent to first induction coil 126 such thatat least a portion of outer bearing ring 132 intersects a magnetic fieldgenerated from first induction coil 126. For example, outer bearing ring132 may be positioned radially adjacent to first induction coil 126,wherein first induction coil 126 radially surrounds at least a portionof outer bearing ring 132. According to additional embodiments, heatingapparatus 120 may comprise additional induction coils and/or maycomprise at least one induction coil positioned such that it is at leastpartially radially surrounded by outer bearing ring 132.

FIG. 16 is a top view of an exemplary heating apparatus 220 in whichbearing orienting member 234 is positioned adjacent a plurality ofbearing elements 231 disposed in an inner bearing ring 233. As shown inthis figure, bearing orienting member 234 may comprise one or morebearing contact parts 286, one or more cantilever rods 287, and atension ring 288. Cantilever rods 287 may be positioned such that theyextend through holes defined in tension ring 288. Bearing contact parts286 may be selectively positioned and/or adjusted on correspondingcantilever rods 287.

Bearing orienting member 234 may be configured such that one or morebearing contact parts 286 contact bearing elements 231 disposed in innerbearing ring 233. According to at least one embodiment, bearing contactparts 286 may exert force against bearing elements 231 such that bearingelements 231 are held within corresponding bearing ring recesses definedin inner bearing ring 233 (see, e.g., bearing ring recesses 66 definedin bearing ring body 62 of bearing ring 32 in FIG. 9). According toadditional embodiments, bearing contact parts 286 may be configured toorient bearing elements 231. Bearing contact parts 286 may exert forceagainst bearing elements 231 when they are positioned on cantilever rods287 as illustrated in FIG. 16. One or more bearing elements 231 may beoriented such that surfaces of bearing elements 231 face in asubstantially radial direction relative to a center of inner bearingring 233, including, for example, a radially outward direction (see,e.g., FIG. 13).

For example, one end of each of cantilever rods 287 may be affixed totension ring 288. As a bearing contact part 286 is positioned on acantilever rod 287, at least a portion of bearing contact part 286 maycontact a bearing element 231 such that a portion of cantilever rod 287is deflected away from bearing element 231 by bearing contact part 286.Accordingly, the deflected portion of cantilever rod 287 may exert forceagainst bearing contact part 286, forcing bearing contact part 286against bearing element 231. According to additional embodiments, two ormore bearing contact parts 286 may be positioned on a single cantileverrod 287. Accordingly, bearing orienting member 234 may be used to orienttwo or more rows or arrays of bearing elements 231 on inner bearing ring233. Additionally, placing two or more bearing contact parts 286 on asingle cantilever rod 287 may enable a greater amount of tension to begenerated in cantilever rod 287 by increasing the deflection ofcantilever rod 287.

According to various embodiments, inner bearing ring 233 may besupported on a rotational support member such that it may be rotatedaround first induction coil 226 (see, e.g., rotational support member 30in FIG. 3). Additionally, inner bearing ring 233 may be disposedadjacent to first induction coil 226 such that at least a portion ofinner ring 233 intersects a magnetic field generated from firstinduction coil 226. For example, inner bearing ring 233 may bepositioned radially adjacent to first induction coil 226. Optionally,first induction coil 226 may be radially surrounded by at least aportion of inner bearing ring 233. According to additional embodiments,heating apparatus 220 may comprise additional induction coils and/or maycomprise at least one induction coil positioned such that it at leastpartially radially surrounds inner bearing ring 233.

FIG. 17 is a perspective view of an exemplary bearing orienting member334. As shown in this figure, bearing orienting member 334 may compriseone or more bearing contact parts 386, one or more cantilever rods 387,and a chuck assembly 350 that includes at least one chuck member 351.The cantilever rods 387 may be positioned such that they extend throughholes 352 defined in the chuck members 351. Bearing contact parts 386may be selectively positioned and/or adjusted on correspondingcantilever rods 387.

Bearing orienting member 334 may be configured such that one or morebearing contact parts 386 contacts a respective bearing element (e.g.,one of contact bearing elements 131, 231 shown in FIGS. 14 and 16,respectively) that is disposed in an inner bearing ring (e.g., one ofouter bearing ring 132 or inner bearing ring 233). Bearing contact parts386 may exert force against the bearing elements by moving thecantilever rods 387 radially inward or radially outward upon movement ofthe chuck members 351 radially inward or radially outward. Thecantilever rods 387 may bend after the contact parts 386 contact thebearing elements and the chuck members 351 continue to move radiallyinward or radially outward.

For example, one end of each of cantilever rods 387 may be affixed to achuck member 351. As a bearing contact part 386 is positioned on acantilever rod 387, at least a portion of bearing contact part 386 maycontact a bearing element (not shown in FIG. 17) such that a portion ofcantilever rod 387 is deflected away from bearing element 331 in aradially outward direction by bearing contact part 386. Accordingly, thedeflected portion of cantilever rod 387 may exert force against bearingcontact part 386 in a radially inward direction, forcing bearing contactpart 386 against the bearing element.

FIG. 18 is a schematic diagram of an exemplary method 400 for heating abearing ring and one or more bearing elements according to variousembodiments. Method 400 may additionally be used for brazing, solderingand/or welding various parts. As illustrated in FIG. 18 (process 402),at least one bearing element may be positioned in a bearing ring and abraze material may be provided for brazing the at least one bearingelement and the bearing ring. For example, a braze material 80 may beplaced in a bearing ring recess 66, and a bearing element 31 may then beplaced in bearing ring recess 66 such that braze material 80 is disposedbetween bearing element 31 and bearing ring body 62, as illustrated inFIG. 9. According to various embodiments, a flux paste may be applied tothe bearing ring, the bearing elements, the braze material, and/or anyadditional parts that may be exposed to heat during brazing of thebearing ring and the one or more bearing elements. In anotherembodiment, flux may be provided in combination with the braze material.The flux paste may comprise any suitable flux composition, including acomposition comprising borax, fluorides, and/or any other suitablecompounds.

During process 404, a current may be passed through an inductor (e.g.,an induction coil) to generate a magnetic field. A current passedthrough the inductor may be an alternating current. During process 406,at least a portion of the bearing ring may be exposed to the magneticfield generated from the inductor. Exposing at least a portion of thebearing ring to the magnetic field generated from the inductor maycomprise heating the bearing ring and the braze material. Exposing atleast a portion of the bearing ring to the magnetic field generated fromthe inductor may also comprise melting the braze material.

According to various embodiments, the bearing ring may be heated to atemperature sufficient to melt the braze material. Additionally, thebearing ring may be maintained at a temperature below a melting and/ordegradation temperature of the bearing ring and/or the bearing elementsdisposed in the bearing ring (e.g., at temperatures of approximately750° C. or higher, polycrystalline diamond may begin to degrade overtime). In at least one embodiment, the bearing ring may be heated to atemperature of between approximately 425° C. and approximately 1480° C.According to additional embodiments, the bearing ring may be heated to atemperature of between approximately 700° C. and approximately 740° C.For example, the bearing ring may be heated to a temperature ofapproximately 710° C.

As at least a portion of the bearing ring is exposed to the magneticfield generated from the induction coil, the bearing ring may increasein temperature relatively quickly due to heat produced in the bearingring as Eddy currents generated in the bearing ring by the magneticfield encounter resistance in the bearing ring material. The relativelyrapid generation of heat in the bearing ring may enable relatively quickbrazing of the bearing elements to the bearing ring through melting ofthe braze material. In at least one embodiment, bearing elements may bebrazed to a bearing ring, such as a steel bearing ring, in a matter ofminutes using a heating apparatus as described herein (see, e.g.,heating apparatus 20 in FIG. 1) as opposed to up to several hours usinga conventional brazing oven, thereby producing the brazed parts morequickly and efficiently. For example, the bearing ring may be exposed tothe magnetic field for several minutes. In at least one embodiment, thebearing ring may be exposed to the magnetic field for a time period ofbetween approximately 3 minutes and approximately 6 minutes. The bearingring may also be exposed to the magnetic field for longer or shortertime periods depending on the size and shape of the bearing ring and/orthe bearing elements and the heating energy applied by inductionheating.

Brazing bearing elements to a bearing ring using a heating apparatus asdescribed herein may produce relatively stronger braze joints thanbrazing using a conventional brazing oven. In at least one embodiment,brazing bearing elements to a bearing ring using a heating apparatus asdescribed herein may reduce or prevent alloying of a braze material withthe bearing ring material, or may reduce or prevent the formation of achromium depleted layer in the bearing ring. Such reduction orprevention of alloying may, in turn, reduce or prevent corrosion at andaround the resulting braze joints, such as corrosion occurring at, forinstance, chromium-depleted zones in the bearing ring.

In one embodiment, exposing at least a portion of the bearing ring tothe magnetic field generated from the induction coil may comprisepositioning the bearing ring such that the induction coil at leastpartially surrounds the bearing ring. For example, as shown in FIG. 4,first induction coil 26 may be positioned such that it radiallysurrounds bearing ring 32. According to additional embodiments, exposingat least a portion of the bearing ring to the magnetic field generatedfrom the induction coil may comprise positioning the bearing ring suchthat the bearing ring at least partially surrounds the induction coil.For example, as shown in FIG. 4, a second induction coil 28 may bepositioned such that bearing ring 32 radially surrounds second inductioncoil 28. Such induction heating configurations may be employedseparately or in combination, without limitation. Furthermore, anysuitable induction heating configuration may be employed, including oneor more inductor of any design (e.g., coils, pancake, etc.).

During process 408, the bearing ring may be rotated relative to theinductor. For example, a bearing ring 32 may be operably coupled to arotational support member 30 such that bearing ring 32 is surrounded byfirst induction coil 26, as illustrated in FIG. 3. Rotational supportmember 30 may then be rotated, causing bearing ring 32 to rotategenerally about rotational axis 54 (see, e.g., rotational axis 54 inFIG. 4). Accordingly, rotational support member 30 may cause bearingring 32 to rotate relative to first induction coil 26. Rotating thebearing ring 32 relative to the induction coil 26 adjacent to thebearing ring 32 may enable the bearing ring to be rotated relative tothe magnetic field generated from the induction coil 26. Accordingly,heat may be generated in the bearing ring 32 relatively consistentlyaround the bearing ring 32 in comparison with a bearing ring that isplaced in a magnetic field but is not rotated. Heating the bearing ring32 relatively consistently may enable the production of a bearing ringthat has bearing elements brazed to it with relatively consistent brazejoints.

FIG. 19 is a schematic diagram of an exemplary method 500 for brazing abearing ring according to one or more embodiments. Method 500 mayadditionally be used for soldering and/or welding various parts. Asillustrated in FIG. 19 (process 502), at least one bearing element maybe positioned in a bearing ring such that a braze material is availableto the at least one bearing element and the bearing ring. As shown byprocess 504, a force may be exerted against a surface of the at leastone bearing element. A force exerted against a surface of the at leastone bearing element may be directed generally toward the bearing ring.During process 506, a current may be passed through a first inductioncoil to generate a magnetic field from the first induction coil. Duringprocess 508, a current may be passed through a second induction coil togenerate a magnetic field from the second induction coil.

As shown by process 510, at least a portion of the bearing ring may beexposed to the magnetic field generated from the first induction coil.During process 512, at least a portion of the bearing ring may beexposed to the magnetic field generated from the second induction coil.Exposing at least a portion of the bearing ring to the magnetic fieldgenerated from the first induction coil and/or the magnetic fieldgenerated from the second induction coil may comprise heating thebearing ring and the braze material. Exposing at least a portion of thebearing ring to the magnetic field generated from the first inductioncoil and/or the magnetic field generated from the second induction coilmay also comprise melting the braze material.

Optionally, exposing at least a portion of the bearing ring to themagnetic field generated from the first induction coil and/or themagnetic field generated from the second induction coil may comprisepositioning the bearing ring such that at least one of the firstinduction coil and/or the second induction coil at least partiallysurrounds the bearing ring. According to additional embodiments,exposing at least a portion of the bearing ring to the magnetic fieldgenerated from the first induction coil and/or the magnetic fieldgenerated from the second induction coil may comprise positioning thebearing ring such that the bearing ring at least partially surrounds atleast one of the first induction coil and/or the second induction coil.As shown by process 514, the bearing ring may be rotated relative to thefirst induction coil and the second induction coil.

FIG. 20 is a schematic diagram of an exemplary method 600 for inductionheating a base member of a superabrasive compact according to variousembodiments. Method 600 may additionally be used for brazing, solderingand/or welding various parts.

As illustrated in FIG. 20 (process 602), a superabrasive compact isprovided. The superabrasive compact comprises a substrate, asuperabrasive material bonded to the substrate, and a base member. Forexample, the superabrasive compact may comprise the bearing element 31described above with reference to FIGS. 7-9. The bearing element 31includes a substrate 74 and a table 72 bonded to the substrate. Thetable 72 may comprise a superabrasive material such as polycrystallinediamond, cubic boron nitride, silicon carbide, or any other suitablesuperhard material. The bearing element 31 may be supported by a bearingring body 62 of a bearing ring 32. The bearing ring body 66 may functionas a base member for the bearing element 31.

During process 604, an inductor is provided proximate to the base memberof the superabrasive compact. For example, the induction coil 26 isshown in FIGS. 3 and 4 provided proximate to the bearing ring body 66 ofthe bearing ring 32. During process 606, the base member of thesuperabrasive compact is rotated. For example, bearing ring 32 may besupported on rotational support member 30 and rotated within an interiorportion of first induction coil 26 when rotational support member 30 israised.

During process 608, the base member is induction heated. In one example,bearing ring body 62 of bearing ring 32 may comprise a generallyconductive material suitable for generating eddy currents in thepresence of a magnetic field generated, such as an electromagnetic fieldgenerated from an induction coil (see, e.g., first induction coil 26 andsecond induction coil 28 in FIG. 4). Eddy currents generated in bearingring body 62 of bearing ring 32 may produce heat within bearing ringbody 62 through Joule heating as the eddy currents pass through andencounter resistance in bearing ring body 62. Such heating may also bereferred to as induction heating.

Any process depicted in the above-disclosed methods may be practiced inany suitable sequence and in any suitable combination, withoutlimitation. The preceding description has been provided to enable othersskilled in the art to best utilize various aspects of the exemplaryembodiments described herein. This exemplary description is not intendedto be exhaustive or to be limited to any precise form disclosed. Manymodifications and variations are possible without departing from thespirit and scope of the instant disclosure. It is desired that theembodiments described herein be considered in all respects illustrativeand not restrictive and that reference be made to the appended claimsand their equivalents for determining the scope of the instantdisclosure.

Unless otherwise noted, the terms “a” or “an,” as used in thespecification and claims, are to be construed as meaning “at least oneof” In addition, for ease of use, the words “including” and “having,” asused in the specification and claims, are interchangeable with and havethe same meaning as the word “comprising.”

What is claimed is:
 1. A heating method, comprising: positioning atleast one bearing element in a bearing ring such that a braze materialis adjacent to the at least one bearing element and the bearing ring;passing a current through an inductor to generate a magnetic field fromthe inductor; exposing at least a portion of the bearing ring to themagnetic field generated from the inductor; rotating the bearing ringrelative to the inductor.
 2. The method of claim 1, further comprisingexerting a force against a surface of the at least one bearing element.3. The method of claim 2, wherein the force is directed toward thebearing ring.
 4. The method of claim 1, wherein exposing at least aportion of the bearing ring to the magnetic field generated from theinductor comprises melting a braze material.
 5. The method of claim 1,wherein exposing at least a portion of the bearing ring to the magneticfield generated from the inductor comprises positioning the bearing ringsuch that the inductor at least partially surrounds the bearing ring. 6.The method of claim 1, wherein exposing at least a portion of thebearing ring to the magnetic field generated from the inductor comprisespositioning the bearing ring such that the bearing ring at leastpartially surrounds the inductor.
 7. The method of claim 1, furthercomprising: passing a current through a second inductor to generate amagnetic field from the second inductor; exposing at least a portion ofthe bearing ring to the magnetic field generated from the secondinductor.
 8. A method of induction heating, comprising: providing asuperabrasive compact comprising: a substrate; a superabrasive materialbonded to the substrate; a base member; providing an inductor proximateto the base member; induction heating the base member.
 9. The method ofclaim 8, further comprising rotating the base member.